Apparatus, method and kit for dustless repair of a damaged wallboard

ABSTRACT

An apparatus, method and kit for dustless repair of a damaged wallboard. The apparatus having an insertion rod which engages a patching element and an insertion brace for inserting the patching element and insertion brace through a hole in the wallboard and adhering the patching element to an inner surface of the wallboard. A dustless method is then provided for patching the hole without producing any environmentally harmful dust. The kit includes all necessary materials for repairing a hole in the wallboard using the dustless method according to this invention.

BACKGROUND OF THE INVENTION

[0001] 1. Field of the Invention

[0002] This invention relates to an apparatus, method and kit for repairing a damaged wallboard without producing environmentally harmful dust.

[0003] 2. Description of Related Art Conventional methods for repairing a damaged wallboard, for example a hole in the wallboard, generally require that a larger hole be cut from the damaged section of wallboard, spanning a width of the wallboard from a first framing stud to an adjacent second framing stud. A piece of drywall material is then cut to a size corresponding to the size of the cut hole. The piece of drywall material is fastened to each framing stud using drywall screws. A patching tape is then applied to the edges of the inserted piece of drywall material and the edges of the wallboard to cover any cracks or spaces between the wallboard and the inserted piece of drywall material. A first layer of filler material, for example patching compound, is applied over the tape to cover the seams and allowed to dry. Once the first layer of filler material is dry, the excess filler material is dry-sanded to smooth the transition from the wallboard to the inserted piece of drywall material. Subsequent layers of filler material are applied to cover the seams until a satisfactory coverage is achieved.

[0004] These conventional methods produce a relatively large amount of dust as a result of the sanding steps required to smooth the layer of filler material applied to the seams, and thus may not be used in areas where dust production is prohibited, for example in sanitized hospital areas, and in offices having sensitive computers and/or equipment which may be damaged if exposed to dust. Further, these conventional methods may be environmentally harmful, for example when used to repair damaged wallboards which have been painted using lead-base paints, such as in older residential buildings. The sanding steps produce dust which may contain environmentally harmful lead paint particles.

[0005] It is apparent from the conventional apparatus and methods for repairing a damaged wallboard, that there is a need for an apparatus and method for repairing a wallboard which is quick, easy and environmentally safe. It is also apparent that there is a need for an apparatus for repairing holes in wallboards having different shapes and/or dimensions.

SUMMARY OF THE INVENTION

[0006] It is one object of this invention to provide an apparatus for repairing a hole in a wallboard which has a patching element that can be easily positioned and secured to an inner surface of the wallboard to close the hole, so that a filler material can be applied to the patching element to fill the hole.

[0007] It is another object of this invention to provide a quick, dustless method for repairing a damaged wallboard, for example a wallboard having a hole, to reduce production of environmentally harmful dust particles.

[0008] It is another object of this invention to provide a kit for repairing a damaged wallboard having an apparatus for repairing a hole in the wallboard and all necessary materials required for a dustless method of repairing a damaged wallboard.

[0009] The above and other objects of this invention are accomplished with an apparatus for repairing a hole in a wallboard having an insertion rod with an insertion end portion which is engageable with a patching element. The patching element is made of a flexible or deformable material, preferably a styrene polymer, and has a surface area greater than an area of the hole which is being repaired. An insertion brace is engageable with the insertion end portion of the insertion rod to support the patching element as it is adhered to an inner surface of the wallboard.

[0010] The patching element is cut to an appropriate size to close or at least cover a portion of the hole. Preferably, the patching element forms an aperture for threadedly engaging with the insertion end portion of the insertion rod. Subsequently, the insertion brace is engaged with the insertion end portion of the insertion rod. The insertion rod is used to insert the insertion brace and the patching element through the hole and into a wall cavity defined by adjacent framing studs and an inner surface of the wallboard.

[0011] The insertion rod is then pulled outwardly from within the wall cavity so that a front surface of the patching element contacts the inner surface of the wallboard. Preferably, an adhesive is applied to the front surface of the patching element to securely retain the patching element against the inner surface of the wallboard. Further, a similar adhesive may be applied to a front surface of the insertion brace to adhere the insertion brace to a back surface of the patching element. The insertion brace supports the patching element and helps to adhere and retain the patching element properly to the inner surface of the wallboard.

[0012] With the patching element positioned properly against the inner surface of the wallboard to close the hole, the insertion brace and the patching element are disengaged from the insertion end portion of the insertion rod and the insertion rod is removed. A first layer of filler material is applied to the patching element. When the first layer of filler material is at least partially dried, the first layer is wet-sanded, whereby water is applied to the outer surface of the first layer with a sponge to keep the first layer wet while the outer surface of the first layer is sanded using a conventional sanding screen. The wet outer surface of the first layer is smoothed using a smoothing surface, for example a squeegee having a rubber end portion.

[0013] A second layer may be applied to the first layer of filler material if necessary to fill the hole. The second layer is then wet-sanded as the first layer was wet-sanded. The wet outer surface of the second layer is smoothed using the smoothing surface. This step can be repeated until a satisfactory repair of the hole has been achieved.

[0014] A kit according to this invention for repairing a hole in a wallboard contains the insertion rod, a deformable patching element which engages with the insertion end portion of the insertion rod, and an insertion brace which engages with the insertion end portion.

[0015] Preferably, but not necessarily, the patching element is made of a styrene polymer which can be cut to an appropriate shape corresponding to the hole in the wallboard, and has an adhesive applied to a front surface. Similarly, the insertion brace is preferably made of a styrene polymer having a greater thickness than the patching element and has an adhesive applied to a front surface.

[0016] The kit may also include a dustless wet-sanding system which may include a smoothing surface, for example a squeegee having a rubber end portion which can be used to smooth the wet layers of filler material applied to the patching element to fill the hole, an applicator, for example a sponge for applying water to the layers of filler material and a sanding screen for wet-sanding the outer surface of the applied layer.

BRIEF DESCRIPTION OF THE DRAWINGS

[0017] The drawings show different features of an apparatus and kit for repairing a damaged wallboard, according to preferred embodiments of this invention, wherein:

[0018]FIG. 1 is a schematic view of an apparatus for repairing a damaged wallboard, according to one preferred embodiment of this invention; and

[0019]FIG. 2 is a schematic view of a kit for repairing a damaged wallboard, according to one preferred embodiment of this invention.

DETAILED DESCRIPTION OF REFERRED EMBODIMENTS

[0020] An apparatus 10 according to this invention can be used for repairing a damaged wallboard, for example a hole in a wallboard. The term “wallboard” includes, for example, drywall sheets, plaster walls and ceilings, and as used throughout this specification and in the claims, the term “wallboard” is intended to mean or relate to a construction material used to construct building walls and ceilings, which are generally supported by a plurality of framing studs or other supporting means. It is apparent that apparatus 10 according to this invention is suitable for repairing a hole in the wallboard having any dimensions and/or shape. For example, apparatus 10 is suitable for repairing a generally circular hole in the wallboard having a diameter of about 2.0 inches to about 16.0 inches.

[0021] Apparatus 10, according to preferred embodiments of this invention, includes an insertion rod 15. Insertion rod 15 may be constructed of stainless steel, aluminum, metal and/or any suitable non-metal material. Insertion rod 15 has an insertion end portion 16 and an opposing handle end portion 17. Preferably, but not necessarily, the insertion end portion 16 is threaded and the handle end portion 17 has a handle, as shown in FIG. 1. Insertion rod 15 can have any suitable length and/or diameter to accommodate a range of suitably-sized patching elements 20.

[0022] As shown in FIG. 1, patching element 20 is engageable with insertion end portion 16 of insertion rod 15. Preferable, but not necessarily, patching element 20 forms an aperture 21 and is threadedly engageable with threaded insertion end portion 16 of insertion rod 15. Patching element 20 is made of any suitable flexible and deformable material. Preferably, patching element 20 is made of a polymer, more preferably a thermoplastic polymer, still more preferably a styrene polymer. Suitable styrene polymers include, but are not limited to, polystyrene (PS), acrylonitrile-butadiene-styrene (ABS), styrene-acrylonitrile (SAN), styrene-butadiene rubber (SBR), styrene-butadiene latexes (SBL), and unsaturated polyester resins (UPR) (fiberglass resins). The term “polymer” includes, but is not limited to, homopolymers, copolymers, such as for example, block, graft, random and alternating copolymers, terpolymers, etc. and blends and modifications thereof. Furthermore, unless otherwise specifically limited, the term “polymer” shall include all possible geometrical configurations of the material. These configurations include, but are not limited to isotactic, syndiotactic and atactic symmetries.

[0023] In one preferred embodiment of this invention, patching element 20 is made of a styrene polymer having a gauge of about 0.010 to about 0.10, preferably about 0.020. Patching element 20 can be cut or shaped using a conventional cutting tool, for example a scissors or a knife, to any shape and/or dimensions to cover at least a portion of the hole. Preferably, but not necessarily, patching element 20 has a surface area greater than an area of the hole which is being repaired to completely close the hole. It is apparent to those having ordinary skill in the art that patching element 20 may be any suitable material which is flexible or deformable to fit through the hole in the wallboard but which has strength to support the filler material applied to fill the hole.

[0024] In one preferred embodiment of this invention, an adhesive, for example a water-based, pressure sensitive adhesive, is applied to at least a portion of a front surface 23 of patching element 20. A suitable adhesive is available from the Industrial Adhesive Manufacturing Co. located in Chicago, Ill. and available under the trade designation N96-35D. The adhesive may be any adhesive known to those having ordinary skill in the art suitable for securely attaching front surface 23 to an inner surface 13 of the wallboard during application of patching element 20 to the wallboard. A release sheet 24 may be positioned over the adhesive to prevent undesired contact, for example during packaging and/or shipping. Release sheet 24 may be made of any suitable material which temporarily adheres to the adhesive but is removable when desired.

[0025] As shown in FIG. 1, an insertion brace 25 is engageable with insertion end portion 16 of insertion rod 15. In accordance with one preferred embodiment of this invention, the insert brace 25 is threadedly engageable with insertion end portion 16 of insertion rod 15. Insertion brace 25 may be constructed of the same or similar material as patching element 20. Preferably, but not necessarily, insertion brace 25 is more rigid or less flexible than patching element 20. In one preferred embodiment of this invention, insertion brace 25 is made of a styrene polymer having a gauge of about 0.010 to about 0.15, more preferably about 0.080. Insertion brace 25 may be any suitable material that can support patching element 20 as patching element 20 and insertion brace 25 are inserted into and moved through the hole and patching element 20 is attached or adhered to back surface 13 of the wallboard. Insertion brace 25 preferably has a surface area less than the surface area of the hole which is being repaired. An aperture 28 is formed by the insertion brace 25 for engagement with the insertion end portion 16 of the insertion rod 15.

[0026] In one preferred embodiment of this invention, an adhesive, for example the same as or similar to the adhesive used to attached front surface 23 to patching element 20, is applied to at least a portion of a front surface 26 of the insertion brace 25. The adhesive may be any adhesive known to those having ordinary skill in the art suitable for securely attaching front surface 26 of the insertion brace 25 to a back surface 22 of patching element 20. A release sheet 27 may be positioned over the adhesive to prevent undesired contact.

[0027] Referring to FIG. 1, a dustless method according to this invention can be used for repairing a damaged wallboard. This dustless method can be preformed relatively quickly because there is no need to cover articles such as furniture, computers, and sensitive equipment near the repair area to protect these articles from dust and/or debris. Additionally, there is little clean up. Further, because this method is dustless, it provides valuable environmental advantages that conventional methods for repairing a damaged wallboard do not provide. For example, the dustless method may by used in hospital areas and other sterile or sanitized environments, in offices having expensive and/or sensitive electronic equipment such as computers, and in residential buildings having lead paint and/or inhabitants with allergies.

[0028] It is apparent that the method according to this invention is suitable for repairing a hole in a wallboard having any dimensions and/or shape. However, this method may be best suited for repairing medium-sized holes, for example holes having a general diameter of about 2.0 inches to about 10.0 inches. Further, the method according to this invention may be used for spackling work such as repairing dings, dents, nail holes, and cracks, as well as drywall work, for example filling seams formed at adjacent edges of drywall sheets, at corners and at edges.

[0029] The method of this invention begins with cleaning any loose pieces of plaster or drywall from the edges of the wallboard forming the hole. Patching element 20 is then provided preferably having a surface area greater than an area of the hole. Patching element 20 may be placed over the hole and may be sized accordingly, preferably having a periphery about 0.5 inches larger than the hole that is being repaired. Patching element 20 is cut to size using any conventional cutting means, for example a scissors or a knife.

[0030] Patching element 20 engages with insertion end portion 16 of insertion rod 15. In one preferred embodiment of this invention, threaded insertion end portion 16 of insertion rod 15 is threadedly engaged with aperture 21 of patching element 20. Insertion brace 25 engages with insertion end portion 16. Preferably, threaded insertion end portion 16 is threadedly engaged with aperture 28 of insertion brace 25. With insertion brace 25 positioned outside patching element 20 with respect to a length of insertion rod 15 as shown in FIG. 1, insertion brace 25 and patching element 20 are inserted into the hole. Patching element 20 made of a flexible material is able to be easily deformed to fit through a smaller hole. Patching element 20 and insertion brace 25 are positioned within a wall cavity defined by adjacent framing studs (not shown) and inner surface 13 of the wallboard. Release sheet 24 and release sheet 27 are removed to expose the adhesive applied to front surface 23 of patching element 20 and front surface 26 of insertion brace 25, respectively.

[0031] Apparatus 10 is moved outwardly from within the wall cavity to mount patching element 20 to inner surface 13 of the wallboard. Front surface 23 of patching element 20 contacts inner surface 13 of the wallboard. As a result of the pressure exerted on front surface 23 of patching element 20 as it contacts inner surface 13 of the wallboard, the adhesive adheres to inner surface 13 and patching element 20 is retained against inner surface 13. Further, front surface 26 of insertion brace 25 is mounted to back surface 22 of patching element 20. Front surface 26 contacts and adheres to back surface 22 of patching element 20. Insertion brace 25 applies pressure to patching element 20 to promote adhesion of patching element 20 to inner surface 13 of the wallboard.

[0032] With the hole closed or covered by patching element 20, a first layer of a suitable filler material, such as plaster, cement, putty and patching compound, is applied to patching element 20 to fill an area defined by the outer surface of patching element 20 and the edges of the wall board. Preferably, but not necessarily, a pulling force is applied to apparatus 10 to retain patching element 20 in secure contact with inner surface 13 of the wallboard as the first layer of filler material is applied. In one embodiment of this invention, insertion brace 25 and patching element 20 may be disengaged from insertion end portion 16 of insertion rod 15 and insertion rod 15 removed before the first layer of filler material is applied.

[0033] After the first layer of filler material is at least partially dried, apparatus 10 is disengaged from insertion brace 25 and patching element 20. The first layer of filler material may be allowed to air-dry or may be dried using a heating apparatus, for example a conventional hair dryer. The first layer of filler material is then wet-sanded with a wet-sanding system having an applicator 46 and a conventional sanding screen 48. The first layer is wetted with water using applicator 46, for example a sponge, to keep the filler material completely wet as the outer surface of the first layer is sanded using a conventional sanding screen. By keeping the filler material completely wet, it ensures that dust will not be produced as a result of sanding the filler material. In accordance with one preferred embodiment of this invention, a sheet of material, for example a sheet of styrene polymer, may be temporarily applied to a portion of the wallboard below the repair area to collect and contain any sanded particles, for example particles of filler material and/or wallboard.

[0034] The outer surface of the first layer is then smoothed using a smoothing surface 50, for example a squeegee or other tool having an edge portion 52 which smooths the outer surface of the first layer upon contact. Preferably, but not necessarily, edge portion 52 is made of a non-stick rubber material.

[0035] A second layer and subsequent layers of filler material may be applied to the previously applied layer in the same or similar procedure in which the first layer was applied. The second layer is then wet-sanded and an outer surface of the second layer is smoothed using smoothing surface 50.

[0036] As shown in FIGS. 1 and 2, a kit 40 according to this invention for repairing a damaged wallboard, for example a wallboard having a hole, includes insertion rod 15. Preferably, but not necessarily, insertion rod 15 has threaded insertion end portion 16. Kit 40 also includes at least one patching element 20. Preferably, patching element 20 is made of a styrene polymer which can be cut to an appropriate shape corresponding to the hole in the wallboard, and has an adhesive applied to a front surface 23. Release sheet 24 is applied to the adhesive to prevent undesired contact before use, for example during packaging and shipping.

[0037] Kit 40 further includes insertion brace 25, which engages with insertion end portion 16 of insertion rod 15 and adheres to back surface 22 of patching element 20 for supporting patching element 20 as patching element 20 is adhered to inner surface 13 of the wallboard. Smoothing surface 50, for example a squeegee, having a rubber end portion 52, smooths the wet outer surface of the layers of filler material to produce a smooth finished surface. Kit 40 may also include a wet-sanding system having an applicator 46, for example a sponge, and sanding screen 48.

[0038] While in the foregoing specification this invention has been described in relation to certain preferred embodiments, and many details are set forth for purpose of illustration, it will be apparent to those skilled in the art that this invention is susceptible to additional embodiments and that certain of the details described in this specification and in the claims can be varied considerably without departing from the basic principles of this invention. 

We claim:
 1. An apparatus for repairing a hole in a wallboard, comprising: an insertion rod having an insertion end portion; a patching element engageable with the insertion end portion, said patching element made of a deformable material and having a surface area greater than an area of the hole; and an insertion brace engageable with the insertion end portion.
 2. The apparatus of claim 1 wherein the insertion rod comprises a handle positioned on a handle end portion of the insertion rod.
 3. The apparatus of claim 1 further comprising an adhesive applied to a front surface of the patching element.
 4. The apparatus of claim 3 further comprising a release sheet positioned on the adhesive.
 5. The apparatus of claim 1 wherein the patching element comprises a styrene polymer.
 6. The apparatus of claim 5 wherein the patching element has a gauge of about 0.010 to about 0.10.
 7. The apparatus of claim 1 wherein the insertion brace comprises a styrene polymer.
 8. The apparatus of claim 7 wherein the insertion brace has a gauge of about 0.010 to about 0.15.
 9. The apparatus of claim 1 further comprising an adhesive applied to a front surface of the insertion brace.
 10. The apparatus of claim 9 further comprising a release sheet positioned on the adhesive.
 11. The apparatus of claim 1 wherein the patching element forms an aperture.
 12. The apparatus of claim 1 wherein the patching element is threadedly engaged with the insertion rod.
 13. A method for repairing a hole in a wallboard, comprising the steps of: providing a patching element having a surface area greater than an area of the hole; engaging the patching element with an insertion end portion of an insertion rod; engaging an insertion brace with the insertion end portion of the insertion rod; inserting the insertion brace and the patching element into the hole; mounting the patching element to an inner surface of the wallboard; applying a first layer of a filler material to the patching element; wet-sanding the first layer; and smoothing an outer surface of the first layer with a smoothing surface.
 14. The method of claim 13 further comprising the steps of: applying a second layer of the filler material to the first layer; wet-sanding the second layer; and smoothing an outer surface of the second layer with a smoothing surface.
 15. The method of claim 13 wherein during the mounting step, a front surface of the patching element is adhered to the inner surface of the wallboard.
 16. The method of claim 13 further comprising the step of mounting the insertion brace to the patching element.
 17. The method of claim 16 wherein a front surface of the insertion brace is adhered to a back surface of the patching element.
 18. The method of claim 13 further comprising the step of disengaging the insertion brace and the patching element from the insertion end portion before the first layer of filler material is applied to the patching element.
 19. The method of claim 13 further comprising the step of disengaging the insertion brace and the patching element from the insertion end portion after the first layer of filler material is applied to the patching element.
 20. The method of claim 19 further comprising the step of at least partially drying the first layer before disengaging the insertion brace and the patching element from the insertion end portion.
 21. The method of claim 13 wherein the wet-sanding step comprises wetting the outer surface of the first layer with a sponge to keep the outer surface of the first layer wet and sanding the outer surface of the first layer with a sanding screen.
 22. A kit for repairing a hole in a wallboard, comprising: an insertion rod having a threaded insertion end portion; a flexible patching element forming an aperture for threaded engagement with the insertion end portion of the insertion rod, the patching element comprising a styrene polymer which can be cut to an appropriate shape corresponding to the hole in the wallboard, and having an adhesive applied to a front surface; an insertion brace forming an aperture for threaded engagement with the insertion end portion of the insertion rod, the insertion brace adherable to a back surface of the patching element for supporting the patching element as the patching element is adhered to an inner surface of the wallboard; a wet-sanding system; and a smoothing surface. 